PDF Maintenance Manual Weichai WD615 Series Euro II Diesel Engine - 2 MB
Keep your Weichai WD615 Series Euro II diesel engine running at peak performance with this comprehensive maintenance manual.
This guide provides detailed instructions for routine service, troubleshooting, and preventative maintenance tasks.
It covers everything from fluid changes to system checks, ensuring you have the information needed for long engine life.
This manual is an essential tool for mechanics and engine owners dedicated to proper upkeep.
Following these procedures will help you maintain engine reliability and efficiency.
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
1.柴油机使用说明
Usage Instructions
1.1 WD615系列客车柴油机代号的含义
The signification of the code of WD615 Series Diesel Engines
W D 6 15 X X X X X
变型产品设计编号
Design code for developed
diversity model
用途代号
Application code:
C––船用柴油机
Marine diesel
基本产品代号 engine
Basic product code D––发电用柴油机
Diesel engine for
柴油机单缸排量 generating set
Single cylinder displacement G––工程机械用柴油机
diesel engine for
缸数 construction
Number of Cylinder machinery
T––推土机用柴油机
柴油机 Diesel engine for
Diesel engine bulldogets
Q––汽车用柴油机
水冷 Diesel engine for
Water cooled trucks
K––客车用柴油机
N––水泥搅拌机
1.2 新柴油机使用须知
Operating notice for new diesel engine
·汽车用柴油机，在汽车使用的最初2000km（约60h）内应限制柴油机转速不超过标定
转速的80%。
For vehicle engines, the engine's rotating speed shoule be limited within 80% of its rated
speed during its initial 2000km running (approximately 60h).
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
2.2.2 保养项目
Maintenance Items
保养项目 更 换 调 整 检 查
Items Replacement Adjustment Inspection
机油 紧固管路管夹
第1次检查
Oil 气门间隙 Tighten pipe clamps
The 1st
机油滤清器 Valve clearance 紧固三角皮带
inspection
Oil filter Tighten V-belts
机油
例行检查 Oil 紧固三角皮带
Periodical inspection 机油滤清器 Tighten V-belts
Oil filter
空气滤清器
机油 Air filter
Oil 进气系统
1级保养 机油滤清器 气门间隙 Air intake system
WD1 Oil filter Valve clearance 紧固管路管夹
燃油滤清器 Tighten pipe clamps
Fuel filter 紧固三角皮带
Tighten V-behs
空气滤清器
机油 Air filter
Oil 进气系统
2级保养 机油滤清器 气门间隙 Air intake system
WD2 Oil filter Valve clearance 紧固管路管夹
燃油滤清器 Tighten pipe clamps
Fuel filter 紧固三角皮带
Tighten V-belts
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
更换机油和机油滤清器，以
清除悬浮在机油中的杂质。
Replace the oil and oil filter to clean
the impurities containing in oil.
注意：应在机油是热的时候
放油
Note:The oil should be drained
off when it iS hot．
32mm 开口扳手
Tool:32mm open-ended wrench
拆下放油螺塞，准备收集 20L
机油。
Remove the whorl plug，prepare a
container tocollect 20L of oil．
注意：热机油会伤人
Note：Hot oil can injure people.
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--- Page 5 ---
WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
13mm 套筒扳手
Tool:13mm sleeve wrench
安装气缸盖罩垫片和气缸盖
罩。
Install the gasket and cylinder
head cover
螺栓拧紧力矩 23N·m( 推荐
数值 )。
The tightening torque of bolt is
23N·m(recommended)
检查三角皮带涨紧力
Check the tension of V-belts
在三角皮带的最大跨距上测
量其挠度：一般要求在强有力的
大拇指压力下，皮带挠度不大于
l0mm。
Measure the flexibility of the V—
belt at the middle of its biggest
span，generally the requirement
result should be less than l0mm
under strong press by your thumb．
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
摇臂机构的润滑
Lubricating for rocker arm
system
1．主油道斜油孔来油
Oil flowing from the oil
branch passage
2．挺柱油孔
Tappet oil hole
3．挺杆油孔
Push rod oil hole
4．摇臂螺钉油孔
Oil hole of rocker arm bolt
5．摇臂油孔
Oil hole of rocker arm
增压器的润滑
Lubricating
turbocharger
1．主油道来油
Oil from the main oil
passage
2．增压器进油口
Oil inlet of turbocharger
3．增压器回油口
The oil outlet of turbocharger
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
7．机油泵惰轮轴螺栓：
Bolt／Oil Pump Idler
Gear Shaft
M10 16mm套筒扳手
T0tal nos．：1 piece M10 bolt
Tool：16mm sleeve wrench
一次拧紧到60 +5N·m
Tighten the bolt with a torque of
60 +5N·m．
拧人前螺纹部位涂乐泰密封
胶242。
Coat the thread with LOCTITE 242
THREADLOCKER before tightening．
8．摇臂座螺栓：
Bolt／Rocker-Arm Support
12根M12
Total nos．：12 pcs M12 bolts
18mm套筒扳手
Tool：18mm sleeve wrench
一次拧紧到100N·m
Tighten these bolts with a torque
of 100N·m．
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
机油压力感应塞：
Induction plug of oil pressure
工作温度 -25~100℃
Operating Temperature：-25~100℃
测量范围 0~500kPa
Measurement Range：0~500kPa
报警压力 45~75kPa
Alarm Pressure：45~75kPa
额定电压 6~24V
Rated Voltage：6~24V
水温表传感器
Sensor of water temperature meter
工作温度 -25~120℃
Operating Temperature：-25 ～ 120℃
额定电压 6~24V
Rated Voltage：6~24V
蓄电池
Battery
2x12V 135Ah 可选用 165Ah 或 195Ah
2×12V 135Ah or 165Ah or 195Ah
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
装上发电机
Install generator．
16mm开口扳手，铁棒
Tool：16mm open-ended
wrench and pontil
安装三角皮带，调好涨
紧度拧紧涨紧轮上M10六角
锁紧螺母。
Install the V-belt and
adjust the tensity, tighten M10
hexagon lock nuts of tightening
pulley．
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
拆下皮带轮和减振器，减
振器和曲轴为过渡配合，必要
时可以轻击减震器。
Remove the pulley and
d a m p e r ，t h e d a m p e r a n d
crankshaft is transition fit，the
damper can be knocked slightly
if it is necessary for removing．
22mm 开口扳手
Tool：22mm open-ended
wrench
拆下齿轮室处六角螺塞。
Remove the hex head plug
screws of gear case．
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
6# 螺丝刀 0.5kg
Tool：6# screwdriver O.5 kg
撑开连轴器与驱动轴连接角
度调节板上的缺口。
Open the gap on the angle
regulating plate connecting the
coupler and the driving shaft.
后推连轴器。
Push shaft coupling backward．
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
将新的喷油器装入喷油器座
孔。
Install new injector into the seat
hole.
注意：装好喷油器后胶圈不
得有压挤现象。
Note：It is not allowed to appear
any mark of pressing rubber
cushion after mounting injector．
安装喷油器固定板。
Install the mounting plate of
injector.
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
9.5排气冒黑烟
Black smoke exhaust
1.进气堵管或排气背压高
清理之
Air intake isn't free or exhaust back pressure is
Clean
too high
2.燃油质量差 清洗及更换
Poor quality of fuel Clean and renew
3.配气或供油定时不对 按规定调整
Incorrect timing of valve gear or fuel supply Adjust according to requirements
4.喷油嘴物化不良 检查，修复或更换
Poor atomizing Check, repair or replace injector
5.喷油泵油量过多 检查并调整(由专业厂进行)
Excessive injection quantity Check and adjust (by manufacturer)
检查排除管路和连接处漏
6.增压系统压力不足
Check and block up the leakage of pipeline and
Insufficient pressure in supercharging system
connector
7.增压器工作失常 检查更换总成
Faults in turbocharger Check and replace
8.中冷器损坏，漏气 更换或修补
Intercooler damaged or leaked Replace or repair
9.冒烟限制器起作用点不对 重新调整(由专业厂进行)
Incorrect working point of smoke-limiter Readjust ( by manufacturer)
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WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
9.18 发电机充电过多
Generator over-charged
1. 蓄电池内部短路 修复或更换
Shorted in battery Repair or replace
2. 调节器电压过高 修复并调整
Voltage of regulator is too high Repair and regulate
3. 调节器搭铁不良 修复
Bad contact in regulator Repair
4. 调节器触头失灵, 污染, 电压线圈或电阻接线断开
修复或更换
Faults in regulator contact, voltage coil or resistance
Repair or replace
connecting wire broken
9.19 发电机有不正常声音
Abnormal sound in generator
1. 发电机安装不当 修复
Incorrect mounting for generator Repair
2. 轴承损坏 更换轴承
Bearing damaged Replace
3. 转动部分已触及固定部分 修复或更换
Moving parts bumping to fixed parts Repair or replace
4. 整流器短路 更换
Rectifier shorted Replace
5. 定子线圈短路 修复或更换
Stator coil shorted Repair or replace
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